Earth coupled geo-thermal energy free building

ABSTRACT

An earth coupled geo-thermal building comprising a plurality of insulated load bearing wall structures, an insulated roof structure, an insulated foundation embedded within the earth a depth sufficient to retain the geo-thermal energy thereunder, one or more energy efficient doors, and an air exchanger for providing clean air to the interior of the building. Each of the wall structures comprises a plurality of spaced-apart stud members having heat transfer resistant wall ties, interstitial blocks of self-supporting insulating material disposed between the stud members, and a surface coating material in contact with the interstitial blocks and embedding the interior and exterior members of the stud members.

BACKGROUND OF THE INVENTION

[0001] The field of the invention relates to building structures, andmore particularly, to composite wall structures, and to methods ofconstructing composite wall structures, comprising a lattice structurewith interstitial material contained therein.

[0002] Conventional building wall structures are usually constructedusing a variety of materials such as wood, steel, masonry, or concrete,and are formed on site by well known construction methods. Theconstruction of building wall structures using conventional materialsand construction methods has certain disadvantages. For example,conventional building wall structures often require significant time toconstruct, which may increase the overall construction cost of thebuilding. Moreover, since conventional building wall structures must beconstructed on site, inclement weather or other factors may result inconstruction delays or increased construction costs.

[0003] In addition, conventional building wall structures are often poorinsulators. Thus, buildings constructed using conventional building wallstructures often require large heating and/or cooling systems tomaintain interior temperatures that are comfortable for the building'soccupants. Moreover, the energy requirements and costs needed to operatethese heating and/or cooling systems can be significant, particularly ifthe building is not located in a temperate climate.

[0004] In an attempt to overcome some of the problems associated withconventional building wall structures, modular walls or wall panels havebeen developed for use as building wall structures. For example,building wall structures have been constructed with modular buildingpanels of plastic foam material reinforced by a lattice of light gaugerod or wire. Building wall structures have also been constructed byerecting a lattice having wall boards attached to both sides thereof.The space between these wall boards is filled with a resin material.Similarly, building wall structures have been constructed using foamedplastic panels having a series of spaced-apart flanges held in positionby transversely connected wires. The space between these plastic panelsis filled with foam, and the exterior surface of the panels is plasticcoated.

[0005] Modular walls or wall panels have a number of advantages overconventional building wall structures. For example, the modular walls orwall panels can be manufactured in a controlled environment, such as afactory. These components can then be delivered to the job site wherethey can be quickly assembled to form the completed building wallstructure. As such, they are generally a less time-consuming alternativeto conventional building wall structures.

[0006] In addition, the above-described modular wall structures aregenerally better insulators than conventional building wall structures.For example, many of the these modular wall structures utilize plasticor foam materials that are poorer heat conductors as compared toconventional building materials such as steel or concrete. However,these modular wall structures typically utilize structural elements thatcompromise the insulating capacity of the finished wall. For example,modular wall structures typically utilize metal ties, bars or wires tohold the inside and outside panels together. These metal componentsprovide pathways for heat to pass through the walls, therebycompromising the insulating capacity of the wall structure.

[0007] The modular walls or wall panels that have been previouslydeveloped also have a number of disadvantages or limitations that makethem impractical or unsuitable for many applications. For example, manyof the above-described modular wall structures lack the strengthnecessary to function as load bearing walls. Many of the above-describedmodular wall structures also lack the resilience necessary to withstandthe rigors of weather. In addition, the materials, such as the resinsand high strength plastics utilized in many of these modular wallstructures, are often expensive and difficult to apply. As aconsequence, the cost of these modular wall structures often compareunfavorably to the cost of conventional building wall structures.

[0008] In view of the above, it is therefore highly desirable to providea building structure having the advantages of modular wall structures,with the low-cost, strength and resilience of conventional buildingwalls. It is also highly desirable to provide a building wall structurehaving an improved insulating capacity. It is also desirable to providea method of constructing a building wall structure having theabove-described features.

BRIEF SUMMARY OF THE INVENTION

[0009] Accordingly, an object of the present invention is to provide anew and improved building structure which overcomes the problems orlimitations of the conventional and modular building structuresdiscussed above. In particular, it is an object of the present inventionis to provide a new and improved building structure for use as theexterior walls or roof of a building structure. It is another object ofthis invention to provide an improved building structure having superiorinsulating qualities as compared with modular and conventional buildingwall structures. It is also an object of the present invention toprovide an improved building structure having superior load bearingcapacities. Finally, it is an object of this invention to provide animproved building structure and building method that is relativelyinexpensive to assemble at the construction site.

[0010] In preferred aspects, the present invention is embodied in acomposite building wall or roof structure comprising a lattice structurewith interstitial material contained therein. In particular, and asdescribed in connection with the illustrative embodiment depictedherein, the present invention comprises a composite building wallstructure having a plurality of vertically disposed stud memberspositioned in a spaced-apart and generally parallel fashion.Interstitial blocks formed of good insulating materials are positionedbetween adjacent stud members and are held together by a plurality ofhorizontal bar members extending between stud members. The interior andexterior surfaces of the wall structure are then covered with a strongand durable material such a concrete.

[0011] In one aspect of the invention, each of the stud memberscomprises a pair of rod members connected together by a number ofcomposite wall ties. The composite wall ties are each formed of acomposite material having a low rate of thermal transfer that reducesthe amount of heat transferred between the interior and exterior surfaceof the wall structure. The resulting building wall or roof structureexhibits a superior insulating capacity.

[0012] In another aspect of the invention, the above-described compositebuilding wall and roof structures are incorporated into an earth coupledgeo-thermal energy free building. In particular, the earth coupledgeo-thermal energy free building utilizes composite building wall androof structures constructed according to the present invention. A lowerportion of the earth coupled geo-thermal energy free building extendsinto the ground so as to utilize the geo-thermal energy of the ground.Windows, doors and other areas that typically have lower insulatingcapacities are kept to a minimum. Air-lock entries are also used tominimize the exchange of heat between the interior of the building andthe ambient surroundings.

[0013] The earth coupled geo-thermal energy free building according tothe present invention tends to maintain a constant interior environment.Consequently, minimal heating and/or cooling systems are required tomaintain interior temperatures that are comfortable for the building'soccupants. The energy demands for the heating and/or cooling systems arelikewise minimal.

[0014] These and other advantages, as well as the invention itself, willbecome apparent in the details of the structure and method ofconstruction as more fully described and claimed below. Moreover, itshould be appreciated that several aspects of the invention can be usedwith other types of building structures and methods.

BRIEF DESCRIPTION OF SEVERAL VIEWS OF THE DRAWINGS

[0015] The above mentioned and other features and objects of thisinvention and the manner of attaining them will become more apparent andthe invention itself will be best understood by reference to thefollowing description of the invention taken in conjunction with theaccompanying drawings wherein:

[0016]FIG. 1 is a perspective view of an interior corner portion of abuilding shell constructed in accordance with the present invention, thebuilding shell comprising an integrally poured concrete floor andfooting, two intersecting walls, two floors of differing construction,and a roof;

[0017]FIG. 2 is a perspective view of a building wall structure of thepresent invention having the surface coating partially removed so as toillustrate the interior lattice assembly;

[0018]FIG. 3 is a vertical cross-sectional view of the building wallstructure shown in FIG. 2;

[0019]FIG. 3A is an enlarged view of portion “A” of the wall structureshown in FIG. 3;

[0020]FIG. 4 is a horizontal cross-sectional view of the building wallstructure shown in FIG. 2;

[0021]FIG. 4A is an enlarged view of portion “B” of the wall structureshown in FIG. 4;

[0022]FIG. 4B is an enlarged view of a portion of an alternative wallstructure depicting the same portion of the wall as shown in FIG. 4A;

[0023]FIG. 4C is an enlarged view of a portion of another alternativewall structure depicting the same portion of the wall as shown in FIG.4A;

[0024]FIG. 5 is horizontal cross-sectional view of a curved buildingwall structure constructed in accordance with the present invention;

[0025]FIG. 6 is cross-sectional view of a building wall structureconstructed in accordance with the present invention showing theconnection thereof to a concrete footing, a concrete floor structure,and a roof structure;

[0026]FIG. 7A is an enlarged view of an alternative wall tie;

[0027]FIG. 7B is an enlarged view of another alternative wall tie; and

[0028]FIG. 8 is a representational view of an energy-free buildingstructure according to the present invention.

DETAILED DESCRIPTION OF THE INVENTION

[0029] Referring to FIG. 1, a building shell 10 is illustrated showingtwo intersecting wall structures 11, 12 and a roof structure 14 of theimproved building structure of the present invention secured to anintegrally poured concrete floor and footing 13. The building shell 10is also shown having floors 16 and 17 extending between the walls 11 and12. The wall structures 11 and 12 and the roof structure 14 generallycomprise the basic building structure 18 illustrated in FIG. 2. In asmuch as many of the elements of the building structure 18 are the same,like reference numerals will be used herein to indicate like structures.

[0030] Referring to FIG. 2, the building structure 18 comprises aplurality of spaced-apart and generally parallel stud members 20. Asused herein, the word “stud” is used generically, and includes similarstructural elements such and roof and floor joists. Each of the studmembers 20 typically comprises a pair of spaced-apart and generallyparallel rod members 22, 24. In the preferred embodiment shown, rodmembers 22, 24 each comprise standard reinforcing bars, and inparticular, #3 Grade 60 rebar. The distance between the rod members 22and 24 is somewhat less than the total thickness of the finished wallstructures 11, 12 or roof structure 14 so that the rod members 22, 24will be encased within the surface coating 90, 92, 94, 96 of thesestructures.

[0031] The rod members 22, 24 are connected together by a series ofcomposite wall ties 26. As best seen in FIGS. 3 and 3A, one end 28 ofeach wall tie 26 is attached to rod member 22, and the other end 30 ofeach wall tie 26 is attached to rod member 24. As best seen in FIGS. 4and 4A, ends 28, 30 each comprise an opening 86 through which rodmembers 22, 24 are inserted. As will be explained below, the length ofwall ties 26 depends on the thickness of the interstitial columns 32 andthe desired spacing between rod members 22 and 24. In the preferredembodiment shown, the spacing between the center of the openings 86 ateach end 28, 30 of the wall ties 26 measures 7.375″, and the overalllength of the wall ties measures 8.25″. In the preferred embodimentillustrated, each of the wall ties 26 is secured to rod members 22, 24by a set-screw 88. Alternatively, wall ties 26 are secured to rodmembers 22, 24 by metal or plastic ties (not shown), by conventionalwelding, or by some other suitable means for fastening these componentstogether.

[0032] As will be explained in greater detail below, the rod members 22,24 and wall ties 26 of the stud members 20 act as an internal truss forsupporting wall structures 11, 12. Moreover, because these componentscan slide or move with respect to each other, the exterior 90 andinterior 92 surfaces of the wall structures 11, 12 can expand orcontract without causing damage or a loss of structural integritythereto. This is particularly important for locations where the outsideair temperature is significantly higher or lower that the interiortemperature of the building structure 10, thereby causing the exterior90 and interior 92 surfaces of the wall structures 11, 12 to expand orcontract with respect to each other.

[0033] In the specific embodiment illustrated herein, wall ties 26 eachcomprise a composite material made of metal and plastic. The compositematerial of the preferred embodiment exhibits low heat transmission toprevent the exchange of heat between the interior bar member 22 and theexterior bar member 24. This prevents heat (or cold) from beingtransferred between the exterior surface 90, 94 and the interior surface92, 96 of the wall 11, 12 and roof 14 structures. The composite materialof the preferred embodiment should also exhibits a sufficientflexibility to permit the exterior 90, 94 and the interior surface 92,96 of the wall 11, 12 and roof 14 structures to expand or contract withrespect to each other. Nevertheless, the composite material must besufficiently strong to hold rod members 22, 24, and consequentlyexterior 90, 94 and the interior surface 92, 96, together.

[0034] In the preferred embodiment, wall ties 26 each comprise acomposite material with a grade of dielectric 44-10 HG, which is achemical and weather resistant molding compound with higher strengththan 44-10, good corrosion resistance, and good electrical propertiesincluding flame and track resistance.

[0035] Of course, it should be appreciated that wall ties 26 can haveany number of shapes, and comprise any number of materials, so long asthe above-described parameters of sufficient strength and low heattransfer are satified.

[0036] As best seen in FIG. 1, an interstitial column 32 is positionedbetween each pair of adjacent stud members 20. In a flat wall or roofstructure, interstitial columns 32 are generally rectangular in shape,and comprise opposing top 34 and bottom 36 end surfaces, opposing edgesurfaces 38 and 40, and opposing interior 42 and exterior 44 sidesurfaces. Accordingly, each stud member 20 is positioned between theedge surfaces 38 and 40 of adjacent pairs of interstitial columns 32. Inthe preferred embodiment shown, stud members 20 are spaced at 2′intervals. Accordingly, interstitial columns 32 are likewise 2′ inwidth.

[0037] As best seen in FIG. 4, the spacing between each pair of adjacentthe stud members 20 determine the distance between edge surfaces 38 and40 (i.e., the width of columns 32). The distance between the interiorand exterior surfaces 42 and 44 (i.e., the thickness of columns 32) isslightly less than the width of stud members 20. In the preferredembodiment shown, interstitial columns 32 each have a thickness of abouttwo inches less than the distance between rod members 22 and 24, and awidth equal to the spacing of stud members 20. As best seen in FIG. 3,each of the interstitial columns 32 may be comprised of a plurality ofinterstitial blocks 46 stacked in an edge-to-edge relationship.

[0038] As best seen in FIGS. 4B and 4C, the shape of the interstitialcolumns 32 can be altered to increase the strength and/or load carryingcapacity of the wall structure 11, 12. For example, and as shown in FIG.4B, the edges of interstitial columns 32 have been tapered so as toincrease the distance between the exterior surface 44 of theinterstitial blocks 32 and rod member 24. As will be explained ingreater detail below, the area surrounding the rod member 24 issubsequently filled with a surface material 90 such as concrete. Thissurface material 90, in combination with the rod member 24, creates astructural member capable of carrying substantial vertical loads. Byincreasing the thickness of the surface material 90 adjacent to the rodmember 24, the load carrying capacity of the wall structure 11, 12 canbe substantially increased.

[0039] The embodiment shown in FIG. 4C is similar that of FIG. 4B.However, the edges of interstitial columns 32 have been notched, asopposed to tapered, so as to increase the distance between the exteriorsurface 44 of the interstitial blocks 32 and rod member 24.

[0040] It should be understood that that the embodiments of FIGS. 4B and4C can also be incorporated along the interior of the wall structures11, 12.

[0041] In the specific embodiment illustrated herein, interstitialcolumns 32 are made of polystyrene foamed material. The advantage ofthis material is that it is readily available at a reasonable cost.However, other filler materials of similar density and insulatingcapabilities can also be used. In the specific embodiment in whichpolystyrene foam is utilized, the building structure of the inventionprovides a wall structure and a roof structure that has betterinsulating properties than wall and roof structures of conventionaldesign. While all of the plastic foam materials being used in modularbuilding panels can be utilized, the invention contemplates that thesematerials would also be provided in block form or column foam and wouldbe constructed on the site as above described. Columns 32 can alsocomprise hollow boxes of plastic, wood or other rigid materials, eitherempty or filled with conventional insulating materials. The inventioncontemplates and the words “block” and “column” and derivatives thereofare used herein to include all of these structures.

[0042] The alternating stud members 20 and interstitial columns 32 ofbuilding structure 18 are bound together to form an integral loadbearing wall or roof structure by a plurality of transversely extendingrods 48. In the preferred embodiment shown, transverse rods 48 compriseconventional ⅜″ reinforcing rods. As best seen in FIGS. 3 and 4,transverse rods 48 are positioned between rods 22, 24 (of the studmembers 20) and the columns 32. Moreover, since columns 32 are nearly asthick as the distance between rods 22 and 24, transverse rods 48 aretypically wedged between the interior 42 and exterior 44 surfaces of thecolumns 32, and the rods 22 and 24, respectively. This arrangement helpsto hold the transverse rods 48 in position, as well as spacing the rods22 and 24 a short distance away from interior 42 and exterior 44surfaces, respectively, of columns 32. As will be explained in greaterdetail below, this permits the surface coating 90, 92 to completelysurround and embed rods 22 and 24.

[0043] Ties 50 may also be used to hold the transverse rods 48 to therods 22, 24. In addition, and depending on the spacing of the wall ties26, the transverse rods 48 may also be positioned so as to rest upon theupper surface of the wall ties 26. In the preferred embodiment shown,transverse rods 48 are alternatively spaced at 4′ intervals along theinterior 42 and exterior 44 surfaces, respectively, of columns 32.

[0044] As set forth above, transverse rods 48 preferably comprisestandard reinforcing bars. Conventional reinforcing bars aremanufactured in finite lengths that are often less than the length ofthe building wall 11, 12 or roof structure 14. As best seen in FIG. 2,individual transverse rods 48 are joined together by overlapping theends thereof for a length sufficient to “hold” the individual transverserods 48 together by frictional forces. In the preferred embodimentshown, transverse rods 48 are overlapped for a distance of approximately30″. Ties 50 are-also typically used to hold the overlapping ends of thetransverse rods 48 together until the surface coating 90, 92 has beenapplied to the wall structure 11.

[0045] Similarly, stud members 20 may be constructed and delivered atthe job site in manageable lengths. However, since stud members 20typically extend the entire height of the building shell 10, separatestud members 20 may have to be connected together in an end-to-endrelationship to provide a continuous stud member 20 of the lengthdesired. This is typically achieved by overlapping rod members 22, 24 asufficient length to “hold” these components together by frictionalforces. Alternatively, the ends of rod members 22, 24 can be fitted withthreaded connectors (not shown).

[0046] It should be appreciated that the size and shape of interstitialcolumns 32, the size and spacing of stud members 20, and the size andspacing of transverse rods 48 will vary depending upon the designcharacteristics of the building shell 10. Likewise, the number, size andspacing of these components will vary depending upon local buildingcodes, the design load to be carried by the wall structure, or the spanof the roof structure. Consequently, it should be understood that theembodiments described above are merely illustrative, and that thepresent invention can be incorporated into any number of variationsutilizing the same basic design structure.

[0047] By way of example, FIG. 5 illustrates a curved building wallstructure made in accordance with the present invention. In thisembodiment, the interstitial columns 32 comprise annular segments asopposed to the rectangular segments described above in connection withFIGS. 2-4. The design and function of the annularly shaped interstitialcolumns 32 are nevertheless the same as those described in connectionwith flat building wall structures. In other words, the curved buildingwall structure shown in FIG. 5 has the same basic design and structureas that of the flat building wall structure shown in FIGS. 2-4.Accordingly, it should be understood that the words “rectangularcolumns” and “rectangular blocks”, as used herein, include columns andblocks comprising annular segments or having other shapes.

[0048] In the preferred embodiments shown, the shape and thickness ofinterstitial columns 32, the size of rod members 22, 24, the length ofcomposite wall ties 26, the spacing of stud members 20, the size andspacing of transverse rods 48, and the thickness surface coatings 90,92, 94, 96 (described below) are selected from a design table. Thedesign table of the preferred embodiment provides certain attributes,such as load capacities and allowable heights or spans, for variouscombinations of these components. Design tables for various buildingstructures, such as wall and roof structures, are not uncommon in thebuilding industry, and provide a simple and quick tool for designingthese structures.

[0049] Referring now to FIGS. 1 and 6, the erection of the wallstructures 11, 12 and the connection thereof to the concrete floorand/or footing 13 will now be described. As best seen in FIG. 6, wallstructure 11 (or 12) sits upon and is connected to footing 13, which istypically constructed prior to the construction of the wall structure11. In the specific embodiment shown, stud members 20 are connected tothe footing 13 by a series of vertical anchor bars 52 that are partiallyembedded in the footing 13. The anchor bars 52 are positioned so as toalign with the exterior rod members 24 of the wall structure 11. In thepreferred embodiment shown, anchor bars 52 are spaced at 2′ centers tomatch the spacing of the stud members 20. In addition, anchor bars 52preferably comprise standard reinforcing bars. More specifically, and byway of example, anchor bars 52 each comprise #3 dowel bars having atotal length of 42″, with a 6″ bend 54 at one end thereof. As shown inFIG. 6, the bend 54 is embedded in the footing 13 and prevents theanchor bar 52 from being pulled out of the footing 13.

[0050] The anchor bars 52 are joined with the rod members 24 byoverlapping the ends thereof for a length sufficient to “hold” thesecomponents together by frictional forces. In the preferred embodimentshown, anchor bars 52 project 30″ above the top of the footing 13,thereby resulting in an overlap of approximately 30″ with the rodmembers 24. Ties 50 are typically used to hold the rod members 24 to theanchor bars 52 until the surface coating 90, 92 has been applied to thewall structure 11.

[0051] The anchor bars 52 are typically positioned in the footing 13 atthe time the footing 13 is constructed. For example, a typical concretefooting 13 is constructed by placing forms (not shown) directly on theground on which the footing 13 is to be constructed. These forms definethe outside walls 56 of the footing 13. Once the forms are in place,then reinforcement 58 may be positioned within the interior volume ofthe forms. The reinforcement 58 holds the concrete 60 together and addsstrength to the footing 13. The anchor bars 52 are also positionedwithin the interior volume of the forms at this time. The concrete 60 isthen poured into the form and allowed to cure.

[0052] Although the embodiment shown only utilizes anchor bars 52connected to the exterior rod members 24 of each stud member 20, itshould be appreciated that anchor bars 52 could also be positioned so asto connect to the interior rod members 22. These additional anchor bars52 may be necessary depending on the building design and/or buildingloads.

[0053] Other methods of attaching the wall structure 11 to the floor orfooting 13 are also contemplated. For example, the anchor bars 52 couldbe installed into the footing 13 after the footing 13 has beenconstructed. This could be accomplished by drilling holes (not shown)into the footing and subsequently securing the anchor bars 52 in theholes with an epoxy or some other adhesive.

[0054] Although the wall structure 11 is preferably connected to thefloor or footing 13 by an anchor device similar to the type describedabove (i.e., anchor bars 52), anchor devices may be unnecessary forsmaller or lightly loaded building structures. In these types ofbuilding structures, it may be sufficient to form a channel (not shown)in the top of the footing 13 into which the lower end of the studmembers 20 can be positioned. Additional details pertaining to some ofthese alternative methods of connecting the wall structure 11 to thefloor or footing 13 are disclosed in U.S. Pat. No. 4,486,993, issuedDec. 11, 1984, and titled “Building Structure and Method ofConstruction”, the specification of which is hereby incorporated byreference.

[0055] As wall structures 11, 12 are being constructed, modificationsmay be made to the wall structures 11, 12 to accommodate floor and/orroof structures. For example, and as shown in FIG. 6, wall structure 11has been modified to provide an attachment structure 62 for supportingroof structure 14. As mentioned above, the roof structure 14 issupported by the wall structure 11 (and/or 12) and the oppositely facingwall structure (not shown). In the preferred embodiment shown in FIG. 6,the roof structure comprises a series of steel joist truss members 64that are designed to span between adjacently facing exterior wallstructures 11 and/or 12. The size and design of the truss member 64 isdetermined by the length of the span, the spacing of the truss members64, the weight of the roof structure 14, and the live loads that theroof structure is designed to carry. Metal decking 68 is typicallyattached to, and spans across, the top of the truss members 64.Insulation, such as foam panels 70, is then secured to the top of themetal decking 68. The foam panels 70 are protected by a waterproof andweather resistant layer 72 that is placed over the top thereof.

[0056] Each end of the truss member 64 is connected to the wallstructure 11 by an attachment structure 62. In the preferred embodimentshown in FIG. 6, the attachment structure 62 comprises a joist bearingchannel 66 that is supported on two or more wall ties 26. Morespecifically, the joist bearing channel 66 is positioned within the wallstructure 11 so as to rest on top of the wall ties 26 adjacent to theinterior rod member 22 of the stud members 20. An end of the trussmember 66 rests on, and is typically welded to, the top of the joistbearing channel 66. The joist bearing channel 66 may be continuous, ormay extend only between those stud members 20 on either side of eachtruss member 66.

[0057] In the preferred embodiment shown, the joist bearing channels 66are also supported by the interior of the wall structure 11. Morespecifically, and as best seen in FIG. 6, the area 74 beneath the joistbearing channel 66 has been filled with the surface coating material 92.This is done by removing the interstitial column 32 in the area 74, andsubsequently permitting this area 74 to be filled with the surfacecoating material 92 at the time surface coating material 92 is appliedto the interior of the wall structure 11. As will be explained ingreater detail below, the surface coating material 92, which istypically concrete, is much more durable than the material used for theinterstitial columns 32. More importantly, the surface coating material92 has a much greater compressive strength than the material used forthe interstitial columns 32. This permits the weight of the roofstructure 14 and any loads thereon to be transferred via the joistbearing channel 66 to the interior surface of the wall structure 11,where it is then distributed across the entire wall structure 11.

[0058] It should be appreciated that other types of roof structures 14could also be utilized in the building structure 10 of the presentinvention. For example, and as shown in FIG. 1, the roof structure 14could be constructed in the same manner as the above described wallstructures 11. More specifically, the roof structure could comprise aseries of stud members 20, with interstitial columns 32 disposed therebetween, and covered with surface coating materials 94, 96. Utilizingthis type of roof structure 14 would eliminate the need for supplementalinsulation (i.e., foam panels 70) and waterproof layering materials 72.

[0059] Anchoring this type of roof structure 14 to the wall structures11, 12 would preferably be accomplished in the same manner as anchoringthe wall structures 11, 12 to the footing 13. For example, and as shownin FIG. 1, “L”-shaped anchor bars 52 could used to structurally connectroof structure 14 with wall structure 11. One leg of an anchor bar 52would be lapped with either rod member 22 or 24 of the stud member 20 inwall structure 11, and the other leg of the anchor bar 52 would belapped with either rod member 22 or 24 of the stud member 20 in roofstructure 14. The subsequent application of the surface coating material90, 92, 94, 96 to both the wall structure 11 and the roof structure 14will result in an integrated structure having a unitary construction.

[0060] In addition to above, other types of roof structures 14, andmethods of connecting these roof structures 14 to the wall structures11, 12, are also contemplated. Details pertaining to some of thesealternative roof structures 14, and methods of connecting these roofstructures 14 to the wall structures 11, 12, are disclosed in U.S. Pat.No. 4,486,993, issued Dec. 11, 1984, and titled “Building Structure andMethod of Construction”, the specification of which is herebyincorporated by reference.

[0061] While the roof structure 14 is shown to form a relatively flatroof, it is well within the scope of those skilled in the art ofbuilding construction to utilize wall structures 11 and 12 to support aconventional sloped roof. A conventional sloped roof can be constructedon and supported by wall structures 11 and 12 in any of theabove-described methods.

[0062] As mentioned above, modifications may be made to the wallstructures 11, 12 to accommodate the connection of floor structures 16,17. As the walls 11 and 12 are being constructed, floor supports 76 areassembled on the studs 20. As shown in FIG. 6, the floor supports 76preferably comprise angle irons that span across two or more studmembers 20. The horizontal flange of each floor support 76 has aplurality of spaced-apart apertures or notches configured to receive rodmembers 22 of studs 20. The floor supports 76 are preferably positionedso as to rest on top of wall ties 26, with the horizontal leg of thefloor support 76 projecting outwardly from the interior face of the wallstructure 11.

[0063] Similar to the above described manner of supporting the joistbearing channels 66, the floor supports 76 are likewise supported by theinterior of the wall structure 11. More specifically, and as best seenin FIG. 6, the area 84 beneath the floor support 76 has been filled withthe surface coating material 92. This is done by removing theinterstitial column 32 in the area 84, and subsequently permitting thisarea 84 to be filled with the surface coating material 92 at the timesurface coating material 92 is applied to the interior of the wallstructure 11. This permits the weight of the floor structure 16, 17, andany loads thereon, to be transferred via the floor support 76 to theinterior surface of the wall structure 11, where it is then distributedacross the entire wall structure 11.

[0064] As shown in FIG. 1, two different floor constructions areillustrated. Floor 16 basically comprises a corrugated steel integraljoist or deck 78 extending between the floor supports 76 of wallstructure 11 and the floor supports 76 in the opposite wall structures(not shown). Concrete is poured on the steel deck 78 and finished in aconventional manner.

[0065] Floor 17 is constructed in a more conventional manner havingfloor joists 80 extending from the floor support 76 of wall structure 11to the floor support in the opposite wall (not shown). As shown in thedrawing, each of the floor joists 80 extends in a spaced-apart andgenerally parallel manner. The most remote floor joists 80 are alsosupported by floor supports 76 in the wall structure 12. Plywoodsub-flooring 82 and conventional flooring materials (not shown) areapplied over the floor joists as desired.

[0066] In addition to above, other types of floor structures 16, 17, andmethods of connecting these floor structures 16, 17 to the wallstructures 11, 12, are also contemplated. Details pertaining to some ofthese alternative floor structures 16, 17, and methods of connectingthese floor structures 16, 17 to the wall structures 11, 12, aredisclosed in U.S. Pat. No. 4,486,993, issued Dec. 11, 1984, and titled“Building Structure and Method of Construction”, the specification ofwhich is hereby incorporated by reference.

[0067] As above described, the building shell 10 is complete except forexterior 90 and interior 92 surface coatings on walls 11, 12, andexterior 94 and interior 96 surface coatings on roof structure 14 (withrespect to the embodiment of FIG. 1). As best seen in FIGS. 3 and 4, asurface coating is applied over both surfaces 42 and 44 of the columns32 of the building structure 18 of the wall structures 11, 12 (and roofstructure 14 of the embodiment of FIG. 1). This coating materialsurrounds the rod members 22, 24 of each stud member 20 and most oftransverse rods 48. In the specific embodiment shown, this surfacecoating is a conventional building material such as concrete, plaster orthe like. Other materials, such as plastics or epoxies, can also beused.

[0068] In the specific embodiment in which concrete is utilized, theconcrete is preferably sprayed onto the surfaces 42, 44 of interstitialcolumns 32 to the desired thickness. As best seen in FIG. 4, controljoints 98 can be used to determine when the desired thickness of thesurface coating 90, 92, 94, 96 is obtained. In the preferred embodimentshown, the control joints 98 are “M”-shaped metal brackets attached tothe outer surface of the transverse bars 48. The control joints 98 havea depth equal to the desired total thickness (as measured from the faceof the transverse bars 48) of surface coatings 90, 92, 94, 96. Concreteis then sprayed onto the surfaces 42, 44 of interstitial columns 32 inthin layers until the control joints 98 have been covered.

[0069] It should be appreciated that the control joints 98 can compriseany number of shapes depending on the required depth and location withinthe wall structure 11, 12.

[0070] Although the above-described procedure involves spraying theconcrete onto the surfaces 42, 44 of interstitial columns 32 to formsurface coatings 90, 92, 94, 96, it should be appreciated that theconcrete can alternatively be poured into forms. For example, concreteforms would be spaced away from the surfaces 42, 44 of interstitialcolumns 32 and positioned so as to define the outer surface of thesurface coatings 90, 92, 94, 96. Concrete is then poured into the gapbetween the forms and the interstitial columns 32 and allowed to cure.Once the concrete has cured, the forms can be removed. This method ofconcrete forming is particularly common for constructing the foundationwalls of smaller buildings and houses.

[0071] Embedding the rod members 22, 24 and most of the transverse bars48 in concrete (or a similarly durable material) results in theconstruction of a wall structure 11, 12 (or the roof structure 14 of theembodiment of FIG. 1) capable of bearing considerable loads. As shown inFIG. 6, the surface coating 90, 92 can also be used to cap the top ofwall structures 11, 12. Conventional paint, wall board, paneling or thelike (not shown) can then be applied to the interior surface coating 92and 96 of the wall structures 11, 12 and roof structure 14,respectively. Similarly, paint and/or other weather protective coatingssuch as tar (not shown) can be applied to the exterior coating 90 and 94of the wall structures 11, 12 and roof structure 14, respectively.

[0072] To facilitate the attachment of surface materials to the wallstructure 11, 12 (or the roof structure 14 of the embodiment of FIG. 1),wall ties 26 can be modified as shown in FIGS. 7A and 7B. In thespecific embodiment shown in FIG. 7A, the interior end 28 of wall tie 26further comprises a flange 100 adapted for attachment to sheet materials102 such as plywood or sheetrock, thereby eliminating the need to anchorthese sheet materials 102 to the interior surface coating 92, 96.

[0073] The wall tie 26 shown in FIG. 7B is similar to the wall tie 26shown in FIG. 7A, but does not include an opening 86 at the interior end28. This type of wall tie 26 would be utilized for wall structures 11,12 not-requiring any interior reinforcing (i.e., interior rod members 24and interior transverse rods 48) or interior surface coatings 92. Inother words, the interior sheet materials 102 would be applied directlyagainst the interior surface 42 of interstitial columns 32. Like theembodiment described in connection with FIG. 7A, the flange 100 of thewall tie 26 provides an anchor point for the sheet materials 102.

[0074] It should be appreciated that wall ties 26 having other types andshapes of attachment structures can also be utilized depending on thenature of the material to be attached thereto.

[0075] It should also be appreciated that the present inventioncontemplates other types of surface materials in addition to thosedescribed above. While conventional building materials are preferableinasmuch as their characteristics are well known and they are readilyavailable at low cost, other more exotic surface materials such asplastic, epoxies or the like can also be utilized.

[0076] As shown representatively in FIG. 8, the above-describedcomposite building wall 11, 12 and roof 14 structures are incorporatedinto an earth coupled geo-thermal energy free building 104. Inparticular, the earth coupled geo-thermal energy free building 104utilizes wall 11, 12 and roof 14 structures constructed in accordancewith the present invention. In the preferred embodiment shown, the wall11, 12 and roof 14 structures each have an insulating rating of at leastR-35. Moreover, all interior structural elements, such as bar joists andcolumns, are isolated from exterior wall and roof components toeliminate, or at least minimize, the transfer of heat between theinterior of the building 104 and the ambient surroundings. Inparticular, all structural or other elements connected between theinterior and exterior surfaces of the building 104 should comprise athermal break, so long as the structural integrity of the building 104is not compromised.

[0077] A lower portion of the earth coupled geo-thermal energy freebuilding 104 extends into the ground 106 so as to utilize thegeo-thermal energy of the ground 106. In particular, the foundation 112and/or floor 114 of the building 104 generally extends beneath the frostline of the ground 106, and similarly has an insulating rating of atleast R-35. Moreover, and as will be explained below, the area of thefoundation 112 and/or floor 114 of the building 104 which extends belowthe frost line of the ground 106 should be maximized to increase thegeo-thermal coupling of the building 104 with the ground 106. Inaddition, that portion of the foundation 112 and/or floor 114 thatextends below the frost line of the ground 106 should not be insulatedfrom the ground 106.

[0078] Windows 108, doors 110, and other building components thattypically have lower insulating capacities are kept to a minimum. To theextent that windows 108 and doors 11 must be incorporated into the wall11, 12 and roof 14 structures of the building 104, these elements shouldbe energy efficient and have proper weather stripping. In the preferredembodiment shown, the doors 110 comprise air-lock entries to minimizethe exchange of heat between the interior of the building 104 and theambient surroundings that is ordinarily created by the opening of thedoors 110.

[0079] As explained above, the earth coupled geo-thermal energy freebuilding 104 of the present invention utilizes the geothermal energy ofthe ground 106, which tends to remain at a constant temperature. Forexample, the ground 106 in most areas of the continental United Stateshas a relatively constant temperature below the frost line that measuresin the range of 50° F. to 70° F., depending on the geographic location.Thus, the thermal mass of the building 104, as well as the interiorthereof, will similarly tend to maintain a constant temperature equal tothat of the ground 106 below the frost line (i.e., in the range of 50°F. to 70° F., depending on the geographic location of the building 104).

[0080] In addition, because of the superior insulating capacity of thebuilding 104, the interior of the building 104 will tend to maintain aconstant temperature irrespective of any fluctuations in the airtemperature of the ambient surroundings. This is because the thermalmass of the building 104 has been isolated from the outside environment.The thermal mass of the building 104 generally includes all of theinternal structural elements or components of the building 104 such asinterior walls, furniture, machinery, etc. Because these elements have amass, they tend to maintain a constant temperature absent exposure tohotter or colder temperatures. Moreover, because these elements areisolated from the outside, they should maintain a constant temperatureirrespective of the outside air temperature.

[0081] Of course, and depending on the type of working conditionsdesired for the interior of the building 104, it is usually desirable tomaintain an interior temperature of approximately 70° F., or at least inthe range of 65° F. to 75° F. Accordingly, additional energy (BTU's)must be added to increase the interior temperature of the building 104to the desired temperature (e.g., 7020 F.). This additional energy isordinarily supplied by people, lighting, machinery, and any other heatproducing equipment operating within the building 104.

[0082] Although the interior of the building 104 will tend to maintain aconstant temperature irrespective of any fluctuations in the airtemperature of the ambient surroundings, it should be appreciated thatthe interior temperature of the building 104 may vary as a result theinternal use of the building 104. For example, the interior temperatureof the building 104 may be increased as a result of heat supplied bypeople, lighting, machinery, and any other heat producing equipmentoperating within the building 104. To the extent that such uses resultin excess heat (BTU's), then such heat is preferably dissipated orvented from the building 104 by air exchangers 116.

[0083] To the extent that additional energy (BTU's) is still required tomaintain the desired interior temperature of the building 104, then anHVAC system 118 may be provided to either raise or lower the temperaturethereof. However, it should be appreciated that the size of, orrequirements for, an HVAC system 118 would be minimal in view of thedesign and function of the earth coupled geo-thermal coupling building104 of the present invention, and would instead be more dependent on thenature of the usage of the building.

[0084] The earth coupled geo-thermal energy free building 104 of thepreferred embodiment further comprises air exchangers 116 to provideproper ventilation and ensure that the air inside the building 104remains clean. In particular, air exchangers 116 are used to change theinterior air from stale to fresh. Air exchangers 116 are also used tomove energy (BTU's) between different areas of the building 104 so as toequalize the temperatures throughout. For example, heat exchangers 116could be used to move warm air from near the roof structure 14 of thebuilding 104 downwardly so as to increase the temperature (i.e., warm)near the floor 114 of the building 104. Although some of these functionscould be accomplished by manually opening windows 108 or doors 110,windows 108 and doors 110 typically lack the controls or monitorsnecessary for effective energy management. Accordingly, air exchangers116 are preferably controlled by a computerized environmental controlsystem 120. The computerized environmental control system 120 would alsooperate the HVAC system 118.

[0085] The improved building structure of the invention provides abuilding structure having many of the properties of modular buildingpanels, yet retaining many of the advantages of conventional on-siteconstruction. The improved building structure of the invention can beused for both exterior and interior walls and roof structures. Inaddition, the improved building structure of the invention can be usedas a load bearing wall structure.

[0086] While there have been described above the principles of thisinvention in connection with specific apparatus, it is to be clearlyunderstood that this description is made only by way of example and notas a limitation to the scope of the invention.

1. An earth coupled geo-thermal building comprising: a plurality ofinsulated load bearing wall structures, each of said wall structurescomprising a plurality of spaced-apart stud members each having anexterior member connected to an interior member by a plurality of heattransfer resistant wall ties, interstitial blocks comprised of agenerally self-supporting insulating material disposed between adjacentpairs of stud members, and a surface coating material in contact withthe interstitial blocks and embedding the interior and exterior membersof said stud members; an insulated roof structure supported by saidplurality of wall structures; an insulated foundation structure forsupporting said plurality of wall structures, said foundation structurebeing embedded within the earth a depth sufficient to retain thegeo-thermal energy under the foundation structure; one or more energyefficient doors disposed in at least one of said plurality of wallstructures; and an air exchanger for providing clean air to the interiorof the building.
 2. The earth coupled geo-thermal building according toclaim 1 wherein said roof structure and said plurality of wallstructures each have an insulation rating of at least R-35.
 3. The earthcoupled geo-thermal building according to claim 1 wherein said roofstructure comprises a plurality of spaced-apart stud members each havingan exterior member connected to an interior member by a plurality ofheat transfer resistant wall ties, interstitial blocks comprised of agenerally self-supporting insulating material disposed between adjacentpairs of stud members, and a surface coating material in contact withthe interstitial blocks and embedding the interior and exterior membersof said stud members.
 4. The earth coupled geo-thermal buildingaccording to claim 1 wherein said energy efficient doors each comprisean air-lock entry system.
 5. The earth coupled geo-thermal buildingaccording to claim 1 further comprising one or more energy efficientwindows disposed in at least one of said plurality of wall structures.6. The earth coupled geo-thermal building according to claim 1 whereinthe interior of the building maintains an air temperature in the rangeof 65° F. to 75° F., said air temperature being maintained withoutheating or cooling energy being supplied by an HVAC system.